Biomass high efficiency hydrothermal reformer

Abstract

A system for the production of synthesis gas, the system including a mixing apparatus configured for combining steam with at least one carbonaceous material to produce a reformer feedstock; and a reformer comprising a cylindrical vessel containing a plurality of coiled tubes, wherein each of the plurality of coiled tubes has a vertical height in the range of from about 40 feet 12.2 m) to about 100 feet (30.5 m) and a coil length that is at least four times the vertical height; at least one burner configured to combust a fuel and provide heat to maintain the reformer at a reformer temperature; at least one outlet for reformer product comprising synthesis gas; and at least one outlet for flue gas produced via combustion of fuel in the burners. A suitable mixing apparatus is also provided.

What is claimed is:  
     
       1. A system for the production of the synthesis gas, the system comprising:
 a mixing apparatus configured for combining steam with at least one carbonaceous material to produce a reformer feedstock; 
 a reformer comprising:
 a cylindrical vessel containing a plurality of coiled tubes, wherein each of the plurality of coiled tubes has a vertical height the range of from about 40 feet 12.2 m) to about 100 feet (30.5 m) and a coil length that is at least four times the vertical height; 
 at least one burner configured to combust a fuel and provide heat to maintain the reformer at a reformer temperature: 
 at least one outlet for reformer product comprising synthesis gas; and 
 at least one outlet for flue gas produced via combustion of fuel in the at least one burner; 
 
 a steam superheater configured to utilize the heat of the flue gas formed in the reformer to produce superheated steam from saturated steam introduced thereto, and provide a reduced temperature flue gas; 
 saturated steam production appratus comprising one or more steam generator, and configured to produce saturated steam via heat transfer with the reduced temperature flue gas, or with both the reduced temperature flue gas and the reformer product gas; 
 a synthesis gas conversion apparatus comprising a Fischer-Tropsch reactor catalyzed to favor the production of liquid hydrocarbons, thus producing a Fischer-Tropsch tailgas, Fischer-Tropsch liquid hydrocarbons, and spent catalyst comprising spent Fischer-Tropsch catalyst and Fischer-Tropsch hydrocarbons separated therewith; and 
 a recycle line fluidly connecting the synthesis gas conversion apparatus with the mixing apparatus, whereby spent catalyst can be introduced thereto. 
 
     
     
       2. The system of  claim 1  wherein at least a portion of the coiled tubes have an inside diameter of at least 2 inches (5.1 cm). 
     
     
       3. The system of  claim 1  wherein each of the plurality of coiled tubes has a coil length that is in the range of from about 400 feet (121.9 m) to about 1000 feet (304.8 m). 
     
     
       4. The system of  claim 1  wherein the reformer is configured to provide a residence time in the range of from about 0.3 s to about 3 s. 
     
     
       5. The system of  claim 1  wherein the metallurgy of the coiled tubes allows operation at a reformer temperature above 1700° F. (927° C.). 
     
     
       6. The system of  claim 1  wherein the metallurgy of the coiled tubes allows operation at a reformer temperature in the range of from about 1700° F. (927° C.) to about 2200° F. (1204° C.). 
     
     
       7. The system of  claim 1  wherein the reformer is operable at a reformer pressure of greater than or equal to about 45 psig. 
     
     
       8. The system of  claim 1  wherein the mixing apparatus and the reformer are fluidly connected via one or more mixing apparatus outlet lines and a distributor configured to provide reformer feedstock to each of the plurality of coiled tubes. 
     
     
       9. The system of  claim 1  wherein the at least one burner is positioned at, near, or below the bottom of the cylindrical vessel. 
     
     
       10. The system of  claim 1  wherein the at least one burner is configured to burn a fuel comprising Fischer-Tropsch tailgas, synthesis gas, methane, or a combination of any two or more thereof. 
     
     
       11. The system of  claim 1  wherein the mixing apparatus comprises one or more cylindrical mixing vessels having a conical bottom and having an inlet for superheated steam connected with the conical bottom and an inlet for at least one carbonaceous material at or near the top of the cylindrical vessel. 
     
     
       12. The system of  claim 1  wherein the mixing apparatus is constructed of suitable material for operation at a pressure of greater than or equal to about 45 psig. 
     
     
       13. The system of  claim 1  wherein the outlets of each of the plurality of coiled tubes are manifolded via an outlet manifold into the at least one outlet for reformer product comprising synthesis gas. 
     
     
       14. The system of  claim 13  wherein the outlet manifold is positioned at, near, or below the bottom of the cylindrical vessel. 
     
     
       15. The system of  claim 1  wherein the at least one outlet for flue gas is positioned at or near the top of the cylindrical vessel. 
     
     
       16. The system of  claim 1  further comprising a steam superheater configured to utilize the heat of the flue gas formed in the reformer to produce superheated steam. 
     
     
       17. The system of  claim 1  further comprising feed preparation apparatus configured to comminute the at least one carbonaceous material, to dry the at least one carbonaceous material, or both. 
     
     
       18. The system of  claim 17  wherein the feed preparation apparatus comprises at least one grinder and at least one separator configured to provide a carbonaceous material having an average particle diameter of less than about 3/16 th  of an inch (0.47 cm). 
     
     
       19. The system of  claim 17  wherein the feed production apparatus is configured to provide a carbonaceous material having a moisture content of less than about 20 weight percent. 
     
     
       20. The system of  claim 1  further comprising one or more recycle lines fluidly connecting the synthesis gas conversion apparatus with the reformer, whereby Fischer-Tropsch tailgas, spent catalyst, or both can be introduced thereto. 
     
     
       21. The system of  claim 20  comprising a recycle line fluidly connecting the synthesis gas conversion apparatus with the at least one burner of the reformer, whereby Fischer-Tropsch tailgas can be introduced thereto and burned therein.